Packaging for freezer pops containing at least one active agent

ABSTRACT

A packaging in the form of a freezer pop for storing a freezable liquid the packaging includes a sealed chamber for storing the freezable liquid formed from at least one inner layer having a sealable edge portion composed of a sealable material and sealed at the edge portion; at least one outer layer composed of a tear and puncture resistant material having an outside surface; at least one intermediate layer which is in sealable contact with both the at least one inner and outer layers, such that all layers are sealable together to form the sealed chamber; and at least one moisture barrier layer in proximity to the outer layer for at least substantially preventing moisture from escaping the sealed chamber for an extended period of time.

The present invention relates to packaging for active agent-containingfreezer pops, and more particularly to a moisture barrier-containingpackaging for freezer pops containing an active agent which needsprotection against moisture loss, such as a pharmaceutical, whichsubstantially reduces or eliminates moisture loss in the packagedproduct.

BACKGROUND OF THE INVENTION

Frozen ice products including “snowballs”, Italian ices, freezer popsand frozen fruit juices have long been popular treats among consumersespecially during the warmer weather months. Frozen ice products of thistype can be carried on sticks, in plastic tubes, or in wax coated papercontainers. No utensils or plates are necessary. One popular frozen iceproduct in particular is the freezer pop, which has been a staple ofsummer treats for many years. The freezer pop can be purchased andconsumed in either as a chilled liquid or as a frozen product. Thefreezer pop is simple and convenient to store and distribute, and lessmessy to consume than other kinds of frozen ice products.

The conventional freezer pop is generally packaged in a substantiallytubular pouch formed from two plastic laminate films adhesively joinedand sealed along the common edges thereof. The sealed plastic laminatefilms, in combination, define a central cavity for enclosing a freezableliquid. The freezable liquid typically contains a flavoring agent, acoloring agent and/or a sweetener. Freezer pop formulations aredescribed in published European Patent Application EP 1 287 747 A2published Mar. 5, 2003, incorporated herein by reference. To form thefreezer pop, a freezable liquid is cooled to temperatures sufficientlylow to freeze the liquid as the freezer pop takes the shape of thecentral cavity. Thereafter, the freezer pop can be dispensed from thepackaging by first cutting off the top end of the pouch to form anopening. The consumer simply presses the bottom end of the pouch toslide the freezer pop out through the opening. Alternatively, thefreezer pop can be consumed in the liquid form by simply drawing thefreezable liquid through the opening in the packaging.

Since freezer pops are seasonal products and are usually kept in thefreezer or on the shelves for relatively short periods of time at atime, extended shelf life is not required for such products. Typically,the packaging film used for conventional freezer pops is fairly perviousto moisture, which can result in significant moisture loss over anextended period of time. The amount of moisture loss can reach 20% to30% or more. As indicated above, due to their seasonal nature,conventional freezer pops are not adversely affected by long-termmoisture loss. Therefore, the packaging used in freezer pops isgenerally designed for storage over a relatively short period of time.

Recently, active agents including, pharmaceuticals, medicaments andnutritional agents and the like have been added to freezer popformulations to provide a unique vehicle for dosing various activeagents to patients including children. However, the packaging used tohouse freezer pops containing such active agents has been found to beinadequate. This is because conventional packaging allows excessivemoisture loss over an extended period of time, and current lawsregulating typical active agents such as pharmaceuticals generallyrequire a shelf life of two years. The amount of moisture loss typicallyencountered in current packaging is considered unacceptable for freezerpops which contain controlled amounts and concentrations of activeagents. Such moisture loss can adversely affect the taste, ingredientbalance, consistency, quality perception, and efficacy of the product.

Accordingly, it would be desirable to develop a packaging for storing afreezable liquid containing an active agent, which greatly enhances theshelf life and quality of the product. It would be further desirable todevelop a packaging for freezer pops, which significantly reduces oreliminates undesirable moisture loss that would otherwise adverselyaffect the taste, quality, ingredient balance, and efficacy of theproduct.

SUMMARY OF THE INVENTION

The present invention relates generally to packaging for storing afreezable liquid containing an active agent so that the active agent maybe administered through a freezer pop. The packaging of the presentinvention includes an arrangement of film layers including a moisturebarrier, which substantially reduces or eliminates undesirable moistureloss, thereby enhancing the quality and storage life of the freezableliquid. In addition, the packaging of the present invention is designedto resist tears and punctures for enhanced child-proof safety.

In one aspect of the present invention, there is provided a packaging inthe form of a freezer pop for storing a freezable liquid, the packagingcomprising:

-   -   a sealed chamber for storing the freezable liquid formed from at        least one inner layer having a sealable edge portion comprised        of a sealable material and sealed at the edge portion;    -   at least one outer layer comprised of a tear and puncture        resistant material having an outside surface;    -   at least one intermediate layer which is in sealable contact        with both the at least one inner and outer layers, such that all        layers are sealable together to form the sealed chamber; and    -   at least one moisture barrier layer in proximity to the outer        layer for at least substantially preventing moisture from        escaping the sealed chamber for an extended period of time.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings in which like reference characters indicate likeparts are illustrative of embodiments of the invention and are notintended to limit the invention as encompassed by the claims formingpart of the application.

FIG. 1 is a perspective view of a packaging containing a freezableliquid in one embodiment of the of the present invention;

FIG. 2 is an enlarged cross sectional view of the packaging along lines2-2 of FIG. 1 in accordance with the present invention; and

FIG. 3 is a schematic cross-sectional view of a packaging illustratingthe layers used to form the sealed chamber in accordance with oneembodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “freezer pop” refers to a consumable freezableliquid contained within a sealed chamber which may be opened by theconsumer to ingest the freezable liquid when in liquid or frozen form.The size and shape of the sealed chamber may vary and is only limited bythe practicality of producing a consumer product.

The term “active agent” refers to any one or more ingredients which maybe incorporated into a freezer pop to provide a beneficial effect to theconsumer upon ingesting the freezer pop. The active agent will typicallybe a therapeutic agent such as pharmaceuticals, medicaments, nutritionalagents, vitamins, neutraceuticals and the like.

The present invention is directed generally to packaging for a freezerpop containing one or more active agents as defined herein. Thepackaging containing the freezer pop, can be placed in a freezer tofreeze the liquid. The packaging of the present invention is alsodesigned to provide sufficient tear and puncture resistance to provideadequate child safety features, while withstanding the effects normallyencountered with freezing and thawing the freezable liquid. Furthermore,the packaging of the present invention includes a moisture barrier thatsignificantly reduces or eliminates moisture loss from the freezableliquid, which would otherwise adversely affect the quality and storagelife of the freezer pop and the active agent that may be containedtherein. Accordingly, the packaging of the present invention providesexcellent protection against moisture loss, thereby maintaining thetaste, quality, ingredient balance and efficacy of the freezable liquidand particularly any active agents contained therein.

Referring to the drawings and first to FIG. 1, there is shown apackaging designed for enclosing a freezable liquid in the form of afreezer pop which may contain an active agent. The packaging identifiedgenerally by reference numeral 10 is shown having a substantiallytubular body 12 with opposing ends 11. The tubular body 12 is formedfrom first and second films 14 and 16 positioned coextensively with oneanother. The first and second films 14 and 16 are each formed with alaminate construction of one or more layers of select materials as willbe described hereinafter. The inner surfaces of the first and secondfilms 14 and 16 are adapted to facilitate sealing of the films togetherthrough suitable sealing means along edge portions 18 thereof. Thesealed first and second films 14 and 16 define a sealed chamber 20 (asbest shown in FIG. 2) extending longitudinally through the tubular body12.

The sealed chamber 20 is adapted to retain a quantity of the freezableliquid 22 which may contain one or more active agents (as best shown inFIG. 2) within the packaging 10. The first and second films 14 and 16are made of select materials and are fabricated to resist tears andpunctures, and withstand the effects normally associated with freezingand thawing of the freezable liquid 22.

The packaging 10 containing the freezable liquid 22 including one ormore active agents may be placed in a freezer for a sufficient time toyield a freezer pop containing the active agent. Upon freezing, thefreezer pop can be consumed by first opening one of the ends 11 of thetubular body 12, and thereafter exerting pressure from the opposed endto urge the frozen liquid out of the open end.

Referring to FIG. 2, the first and second films 14 and 16 are positionedso that opposing inner surfaces 23 a and 23 b face one another andthereby form an inner boundary of the sealed chamber 20 which enclosesthe freezable liquid 22. The edge portions 18 are maintained in sealingcontact with one another at contact areas 19 through suitable sealingmeans as known in the art (e.g. an adhesive or through heat sealing).The outer surfaces 25 a and 25 b of the respective films 14 and 16 whichform the exterior surface of the freezer pop and thereby do not contactthe freezable liquid may be adapted to permit printing thereon. Theprinting, for example, may be required instructions for consuming afreezer pop, which contains an active agent. The first and second films14 and 16 may be transparent to enable the product to be visible to theconsumer, if desired.

The arrangement and composition of the layers of material forming anembodiment of the packaging will now be explained with reference to FIG.3. Referring to FIG. 3, there is shown the relative positioning of thefirst and second films 14 and 16 of the packaging 10 with theunderstanding that the dimensions of the different layers comprisingfirst and second films 14 and 16 depicted herein are not drawn to scaleor shown in proportion to one another. The first and second films 14 and16 each include one or more discrete layers of polymer materialsarranged to form the sealed chamber 20, which is occupied by thefreezable liquid 22.

The first and second films 14 and 16 each include at least one adhesivelayer 24 (a single layer is shown) in contact with the freezable liquid22, one or more intermediate layers 26 (a single intermediate layer isshown) overlaying the adhesive layer 24, and at least one outer layer 28(a single outer layer is shown) overlaying the intermediate layer 26.

The adhesive layers 24 form the base portion of the laminate filmconstruction of the first and second films 14 and 16 and are the layerswhich are in direct contact with the freezable liquid through therespective bottom surfaces thereof. The adhesive layers 24 are sealinglyengaged to one another along the edge portions 18 of the first andsecond films 14 and 16. The adhesive layer 24 may be composed of asuitable adhesive material, including, but not limited to, pressuresealable and/or heat sealable materials such as, for example,low-density polyethylene-linear low-density polyethylene (LDPE-LLDPE).The thickness of the adhesive layer 24 may typically range from about100 gauge to 400 gauge. The selection of a suitable adhesive materialmay also provide tear and puncture resistant properties to thepackaging. For example, LLDPE is known to exhibit both tear and punctureresistance.

One or more intermediate layers 26 overlay the outer surface of theadhesive layer 24. The intermediate layer 26 draws the adhesive layer 24and the at least one outer layer 28 together into a single laminatestructure, and forms a transition layer to provide a structural bondbetween the adhesive layer 24 and the outer layer 28 which contributesto providing a desirable childproof product which is both tear andpuncture resistant. The intermediate layer 26 is typically composed ofmaterial such as low-density polyethylene (LDPE) and has a thicknessgenerally from about 9 to 12 lbs/m², preferably about 10.8 lbs/m².

The at least one outer layer 28 forms the main structure of the laminatefilm 14 and 16, and overlays the outside surface of the intermediatelayer 26. The outer layer 28 provides the laminate films 14 and 16 withthe structural integrity necessary to provide the packaging 10 with therequisite tear and puncture resistance. The outer layer 28 provides thepackaging with tear and puncture resistance sufficient to preventchildren from accidentally gaining access to the freezable liquid. Tearand puncture resistance properties for this purpose would be known tothose skilled in the art. The outer layer 28 is composed of a tear- andpuncture-resistant material such as, for example, polyethyleneterephthalate (PET), oriented polypropylene (OPP), and biaxial nylon.The thickness of the at least one outer layer 28 is typically of fromabout 36 gauge to 200 gauge, and preferably about 92 gauge.

The packaging 10 further includes at least one moisture barrier layer30, which may be located between the intermediate layer 26 and the outerlayer 28 and/or may overlay the outside surface of the outer layer 28.In the specific embodiment of FIG. 3, the moisture layer 30 ispositioned in both locations for purposes of illustration. The moisturebarrier layer 30 is selected from materials which are capable ofproviding sufficient moisture barrier properties to the packaging 10 soas to reduce moisture loss from the freezable liquid 22 for an extendedperiod of time, typically up to or exceeding two years. The moisturebarrier layer 30 provides the packaging with a water transmission rateof less than 0.25 gms/100 inch²/24 hours at 100° F., 90% RH.

The moisture barrier layer 30 may be selected from low moisturetransmission materials including, for example, low moisture transmissionpolymer films such as, for example, polyvinylidene chloride (PVDC), andpolychlorotrifluoroethylene (PCTFE), coatings of silicon oxide and/oraluminum oxide and metal foils such as, for example, aluminum foil. Thepreferred low moisture transmission material is polyvinylidene chloride(PVDC). The moisture barrier layer is typically fabricated with athickness of up to 2 gauge.

The packaging of the present invention is particularly suited to storefreezable liquids containing one or more active agents, but may beemployed for freezable liquids which do not contain an active agent.Suitable freezable liquid formulations in which an active agent may beadded are disclosed in EP 1287747A2, as previously described.

The frozen liquid in the form of a freezer pop is preferably fastdissolving. The term “fast dissolving” as used herein means that thefrozen liquid dissolves in less than 30 seconds, preferably less than 15seconds, and more preferably less than 10 seconds, after placing thefreezer pop in the oral cavity. To freeze the above-described freezableliquid, the packaging containing the freezable liquid is placed in afreezer at a temperature below 0° C., preferably from −5° C. to −20° C.

EXAMPLE

A packaging for a freezer pop formulation containing dextromethorphanhydrobromide as an active agent is prepared by forming a packagingcomprising two films sealed together to form a chamber for storing thefreezer pop formulation.

The two films have the same or similar construction to that shown inFIG. 3. The adhesive layer is a low-density polyethylene-linearlow-density polyethylene (LDPE-LLDPE) having a thickness of about 200gauge. The intermediate layer is a low-density polyethylene (LDPE)having a thickness of about 10.8 lbs/m². The outer layer is polyethyleneterphthalate coated with saran and has a thickness of about 50 gauge.

A moisture barrier layer of polyvinylidene chloride is provided on theouter surface of the outer layer and has a thickness of up to 2 gauge.The freezer pop formulation is stored in a holding tank and then passedthrough a plate heat exchanger for pasteurization. The pasteurizedformulation is sent to a stainless steel feed tank. The formulation isloaded into the packaging in a conventional filling device. Such fillingdevices are commonly known in the art. It is preferred to use a devicewhich is serviced by volumetric pumps. In the present instance thedevice is comprised of sets of eight bars on a single head feed line.The filing line is serviced by eight volumetric pumps—one for eachfilling line. The 8-bar set is vertically perforated so that anindividual bars may be separated from the rest of the bars foradministration.

1. A packaging in the form of a freezer pop for storing a freezableliquid, the packaging comprising: a sealed chamber for storing thefreezable liquid formed from at least one inner layer having a sealableedge portion comprised of a sealable material and sealed at the edgeportion; at least one outer layer comprised of a tear and punctureresistant material having an outside surface; at least one intermediatelayer which is in sealable contact with both the at least one inner andouter layers, such that all layers are sealable together to form thesealed chamber; and at least one moisture barrier layer in proximity tothe outer layer for at least substantially preventing moisture fromescaping the sealed chamber for an extended period of time.
 2. Thepackaging of claim 1 wherein the at least one moisture barrier layer islocated between the intermediate and outer layers.
 3. The packaging ofclaim 1 wherein one of the moisture barrier layers overlays the outsidesurface of one of the outer layers.
 4. The packaging of claim 1 whereinthe packaging has a water vapor transmission rate of less than 0.25gms/100 inch²/24 hours at 100° F., 90% RH.
 5. The packaging of claim 1wherein the at least one moisture barrier layer is comprised of a lowmoisture transmission material selected from the group consisting of lowmoisture transmission polymer films and metal foils.
 6. The packaging ofclaim 5 wherein the low moisture transmission polymer film is selectedfrom the group consisting of polyvinylidene chloride andpolychlorotrifluoroethylene.
 7. The packaging of claim 5 wherein themetal foil is aluminum foil.
 8. The packaging of claim 1 wherein thethickness of the at least one moisture barrier layer is up to 2 gauge.9. The packaging of claim 1 wherein the sealable material is an adhesivematerial.
 10. The packaging of claim 9 wherein the adhesive material isselected from the group consisting of pressure sealable adhesivematerials, heat sealable adhesive materials, and combinations thereof.11. The packaging of claim 10 wherein the sealable adhesive material islow-density polyethylene-linear low-density polyethylene.
 12. Thepackaging of claim 1 wherein the sealable material is in the form of asealable layer having a thickness of from 100 to 400 gauge.
 13. Thepackaging of claim 1 wherein the tear and puncture resistant material isselected from the group consisting of polyethylene terephthalate, andoriented polypropylene, and biaxial nylon.